U.S. patent application number 12/044520 was filed with the patent office on 2008-09-11 for flavored taco shells.
Invention is credited to ANTHONY W. RICHARDS.
Application Number | 20080220144 12/044520 |
Document ID | / |
Family ID | 39628991 |
Filed Date | 2008-09-11 |
United States Patent
Application |
20080220144 |
Kind Code |
A1 |
RICHARDS; ANTHONY W. |
September 11, 2008 |
FLAVORED TACO SHELLS
Abstract
A flavored corn tortilla taco shell is provided. The flavored
corn tortilla taco shell has a first sidewall element, a second
sidewall element, a substantially flat base element of defined
width, a first curved element interconnecting the first sidewall
element to the flat base element; and a second curved element
interconnecting the second sidewall element to the flat base
element. Methods of fabrication are disclosed.
Inventors: |
RICHARDS; ANTHONY W.;
(Poplar, WI) |
Correspondence
Address: |
GENERAL MILLS, INC.
P.O. BOX 1113
MINNEAPOLIS
MN
55440
US
|
Family ID: |
39628991 |
Appl. No.: |
12/044520 |
Filed: |
March 7, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60893402 |
Mar 7, 2007 |
|
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Current U.S.
Class: |
426/622 |
Current CPC
Class: |
A21D 13/33 20170101;
A23L 7/13 20160801; A21D 13/42 20170101; A23P 20/20 20160801; A21C
15/025 20130101 |
Class at
Publication: |
426/622 |
International
Class: |
A23L 1/10 20060101
A23L001/10 |
Claims
1. A flavored corn masa dough composition, comprising: about 47-57%
corn masa flour by weight (dry basis); about 39-49% by weight
moisture; 1-5% seasoning blend by weight (dry basis); and 1-5% salt
by weight (dry basis).
2. The flavored corn masa dough of claim 1 wherein the corn masa
flour is yellow coarse ground masa flour.
3. The flavored corn masa dough of claim 1 wherein the seasoning
blend contains dairy ingredients.
4. The flavored corn masa dough of claim 1 additionally comprising
less than 1% added fat.
5. The flavored corn masa dough of claim 1 additionally comprising
less than 1% preservatives.
6. The flavored corn masa dough of claim 1 additionally comprising
less than 1% food color.
7. The flavored corn masa dough of claim 1 additionally comprising
0.1% up to about 4% or less ground deep-fat fried flavored taco
shells.
8. A flavored cooked corn masa tortilla article fabricated from
corn masa dough comprising: about 47-57% corn masa flour by weight
(dry basis); about 15-30% by weight moisture; 1-5% seasoning blend
by weight (dry basis); 1-5% salt by weight (dry basis); and 0.1-1%
added fat by weight (dry basis).
9. A flavored corn masa taco intermediate article, comprising: A
molded flavored corn masa tortilla having a first sidewall and a
second sidewall interconnected by a substantially flat base, the
flavored corn masa tortilla configured with a lip distance is 2.5
to 3 times the width of the base.
10. The flavored corn masa taco intermediate article of claim 9
wherein the lip distance is 65 to 75 millimeters.
11. The flavored corn masa taco intermediate article of claim 9
mounted upon a mold.
12. The flavored corn masa taco intermediate of claim 9 in the form
of a hot deep-fat fried corn tortilla taco shell with a flexible or
plastic body.
13. A deep-fat fried flavored corn tortilla taco shell article
fabricated from a corn masa dough, comprising: about 47-57% corn
masa flour by weight (dry basis); about 2-8% by weight moisture;
1-5% seasoning blend by weight (dry basis); 1-5% salt by weight
(dry basis); and having 15-30% absorbed cooking oil by weight (dry
basis).
14. The deep-fat fried flavored corn tortilla taco shell of claim
13 wherein at least a portion of the salt is topically applied.
15. The deep-fat fried flavored corn tortilla taco shell of claim
13 wherein at least a portion of the seasoning blend is topically
applied.
16. The deep-fat fried flavored corn tortilla taco of claim 13
substantially free of topically applied salt and seasoning
blend.
17. A flavored self-standing, flavored corn masa tortilla taco
shell article being dimensionally stable at room temperature,
comprising: about 47-57% corn masa flour by weight (dry basis);
about 2-8% by weight moisture; 1-5% seasoning blend by weight (dry
basis); 1-5% salt by weight (dry basis); having 15-30% absorbed
cooking oil by weight (dry basis); and a. a first sidewall and a
second sidewall interconnected by a substantially flat base, the
flavored taco shell configured so the height of the taco shell is
approximately 1.50 to 4.0 times the width of the base.
18. The flavored taco shell of claim 17 wherein the base is "W"
shaped.
19. The flavored taco shell of claim 17 wherein the height of the
flavored taco shell is about 2.0 to 3.0 times the width of the
base.
20. The flavored taco shell of claim 17 wherein the height of the
flavored taco shell is about 2.0 to 2.5 times the width of the
base.
21. A flavored stable, self-standing, taco shell, comprising: a. a
first sidewall and a second sidewall interconnected by a
substantially flat base, the flavored taco shell configured so the
lip distance of the flavored taco shell is about 40 to 60
millimeters and the width of the base is at least about 18
millimeters.
22. The flavored taco shell of claim 21 wherein the base is "W"
shaped.
23. The flavored taco shell of claim 21 wherein the base width of
the flavored taco shell is about 20 millimeters or greater.
24. The flavored taco shell of claim 21 wherein the base width of
the flavored taco shell is about 22 millimeters or greater.
25. The flavored taco shell of claim 21 wherein the base width of
the flavored taco shell is about 25 to 26 millimeters.
26. The flavored taco shell of claim 21 wherein the lip distance of
the flavored taco shell is about 45 to 55 millimeters and the base
width of the flavored taco shell is at least about 20 millimeters
or greater.
27. The flavored taco shell of claim 21 wherein the lip distance of
the flavored taco shell is about 45 to 55 millimeters and the base
width of the flavored taco shell is about 22 millimeters or
greater.
28. The flavored taco shell of claim 21 wherein the lip distance of
the flavored taco shell is about 45 to 55 millimeters and the base
width of the flavored taco shell is about 25 to 26 millimeters.
29. The flavored taco shell of claim 21 wherein the lip distance of
the flavored taco shell is about 50 to 55 millimeters and the base
width of the flavored taco shell is about 22 millimeters or
greater.
30. A method of making a flavored stable, self-standing, taco
shell, comprising: providing a flavored tortilla; and placing the
flavored tortilla on a mold configured so the resulting flavored
taco shell has a first sidewall and a second sidewall
interconnected by a substantially flat base, and the height of the
resulting flavored taco shell is about 1.50 to 4.0 times the base
width of the flavored taco shell.
31. The method of claim 30 wherein the height of the resulting
flavored taco shell is about 1.75 to 3.35 times the width of the
base.
32. The method of claim 30 wherein the height of the resulting
flavored taco shell is about 2.0 to 3.0 times the width of the
base.
33. The method of claim 30 wherein the height of the resulting
flavored taco shell is about 2.0 to 2.5 times the width of the
base.
34. A flavored stable, self-standing, taco shell, comprising: a. a
first sidewall element; b. a second sidewall element; c. a
substantially flat base element; d. a first curved element
interconnecting the first sidewall element to the flat base
element; and e. a second curved element interconnecting the second
sidewall element to the flat base element.
35. The flavored taco shell of claim 34 wherein at least one the
elements has a thickness of less than 1.5 millimeters.
36. The flavored taco shell of claim 34 wherein at least one the
elements has a thickness of at least 1.5 millimeters.
37. The flavored taco shell of claim 34 wherein at least one of the
curved elements has a radius of about 6 millimeters or greater.
38. The flavored taco shell of claim 34 wherein at least one of the
curved elements has a radius of about 3 to 6 millimeters.
39. The flavored taco shell of claim 34 wherein at least one of the
curved elements has a radius of about 3 millimeters or less.
40. A method of making a flavored stable, self-standing, taco
shell, comprising: providing a flavored tortilla; and a. placing
the flavored tortilla on a mold configured so the resulting
flavored taco shell has a first sidewall element, a second sidewall
element, a substantially flat base element, a first curved element
interconnecting the first sidewall element to the flat base
element, and a second curved element interconnecting the second
sidewall element to the flat base element.
41. The flavored taco shell of claim 40 wherein at least one the
elements has a thickness of less than 1.5 millimeters.
42. The flavored taco shell of claim 40 wherein at least one the
elements has a thickness of at least 1.5 millimeters.
43. The method of claim 40 wherein at least one of the curved
elements has a radius of about 6 millimeters or greater.
44. The method of claim 40 wherein at least one of the curved
elements has a radius of about 3 to 6 millimeters.
45. The method of claim 40 wherein at least one of the curved
elements has a radius of about 3 millimeters or less.
46. A method of making a deep-fat fried flavored self-standing,
taco shell, comprising the step of: providing a flavored tortilla;
a. placing the flavored tortilla on a mold configured so the
resulting flavored taco shell has a first sidewall element, a
second sidewall element, a substantially flat base element, a first
curved element interconnecting the first sidewall element to the
flat base element, and a second curved element interconnecting the
second sidewall element to the flat base element; b. deep-fat
frying the molded flavored tortilla shell in 165.degree. C. cooking
oil for 30 to 40 seconds; c. removing the deep-fat fried flavored
self-standing taco shell from the cooking oil; and, d. subsequently
the mold; and, e. resting the deep-fat fried flavored self-standing
taco shell on its side to cool to room temperature and harden to
form a finished crispy shell.
47. A tortilla fabricated from the flavored masa dough of claim
2.
48. The article of claim 17 in a plurality of pieces in a nested
array.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35
U.S.C. 119(e)(1) of a provisional patent application Ser. No.
60/893,402, filed Mar. 7, 2007, which is incorporated herein by
reference in its entity.
FIELD OF THE INVENTION
[0002] The present invention relates to edible food shells and to
masa dough compositions useful as a intermediate product in their
preparation. More specifically, the present invention relates to
flavored taco shells and to their methods of preparation.
BACKGROUND OF THE INVENTION
[0003] This patent application describes an improvement to taco
shells including self standing taco shells to provide flavored taco
shells prepared from a flavored masa dough. Taco shells made from
corn are commonly available in the traditional U-shaped design and
have a mild corn flavor. More recently taco shells have evolved to
include improved versions that are self standing as described in
patent application PCT/US02/36474 Square Bottom Taco Shell, Kovich
et al., and U.S. Pat. No. 5,993,871 Stable Self Supporting Taco
Shell, Beehler. Self standing taco shells, unlike U-shaped taco
shells, rely upon their unique shape to stand freely without the
assistance of a secondary holding device or human intervention. The
shape of self standing tacos is created by molding and frying
tortilla shells into any of the known self standing shape designs
see PCT/US02/36474 or '871. The shape of self standing tacos was
purposely designed to be useful for filling standing shells with
such items as cooked meat or poultry, cheese, sour cream, lettuce,
tomatoes, black olives, taco sauce etc. prior to consumption. Since
self standing taco shells are free standing and quite stable, a
consumer can fill and eat a self standing taco rather easily
without undue fear of a filled shell falling over and making a
mess.
[0004] Consumer acceptance of self standing taco shells has been
appreciably high. To capitalize upon the success of self standing
taco shells and to continue to increase consumer interest and
demand for taco shells it is desirable to now flavor taco shells.
The addition of new flavor varieties to existing products in this
manner is a common and highly successful marketing strategy known
as creating line extensions. Of course, topically flavored fried
snack products fabricated from fried masa dough pieces are well
known as well as other fried snack products. These products are
typically consumed without eating utensils and thus are
colloquially referred to as "finger foods". Typically, an
unflavored base is prepared from an unflavored masa dough that is
formed into pieces and deep fat fried. While still warm, a topical
seasoning or flavor coating can be applied typically comprising a
dry blend of salt and various seasoning dry powders such as dried
cheese solids. While useful, the topical application of dry
seasoning flavors results in a product that often undesirably
results in products that transfer residual amounts of the dry
powder topical seasoning blend from the finger food to the
consumer's fingers resulting in an undesirable untidiness. Also,
food products prepared from flavored dough formulations that do not
include a topical seasoning are well known. However, while
incorporating flavors into traditional U-shaped taco shells and
more preferably self standing taco shells is highly desired there
are significant challenges to manufacturing, packaging and consumer
acceptance of flavored taco shells.
[0005] Commonly taco shells are made by deep-fat frying white or
yellow corn tortillas held in a mold. Corn tortillas are made from
masa dough. One generally accepted way to make masa dough is to
heat dried corn kernels in a slightly corrosive solution of water
and lime. This process assists in removal of the kernel's tough
outer skin. Once the skins are removed, kernels can be rinsed and
boiled in fresh water, drained and mashed into masa dough. Small
portions of masa dough are flattened into the desired diameter and
thickness for tortillas and cooked very quickly often on each side
on a hot flat surface. Creating masa dough of the correct
consistency is an essential step in the creation of corn tortillas.
Adding flavor ingredients to masa dough prior to forming flavored
tortillas and subsequent molding and frying flavored tortillas into
flavored taco shells significantly impairs the manufacturing
process and yields a high number of unacceptable shells
characterized in part by an unacceptably narrow gap between the
sides of the shell. This problem is apparent upon removal of hot
flavored corn tortilla taco shells from the fryer. Hot flavored
corn tortilla taco shells are plastic and pliable upon removal from
the fryer. Gravity immediately acts upon hot shells causing a
predictable collapse in the overall structure of the self standing
taco shell not exhibited with unflavored masa dough. One theory as
to the cause of this problem is that flavor ingredients disrupt the
natural cohesive structure of prepared masa dough creating a softer
less cohesive dough. This problem can also be a localized
phenomenon whereby the opening of flavored self standing taco
shells closes appreciably due to a convergence of the opposed
sidewalls.
[0006] Collapsed or closed U-shaped and self standing taco shells
are difficult to handle and nearly impossible to stack and package.
Consumers find collapsed or closed traditional U-shaped and self
standing taco shells undesirable because they are difficult to fill
and they hold less taco filling. Additionally, in a collapsed or
closed state self standing taco shells often will not function as
self standing food items.
[0007] Flavoring large flour tortilla shells gained great
popularity as wrap sandwiches dominated the food service landscape
in the late 90's and beyond. However, wheat flour tortillas differ
greatly from corn masa tortillas. Wheat flour tortillas have a
unique capacity for accepting ground garden vegetable and juice
additives. Due in large part to the nature of wheat flour dough,
the process of adding ground garden vegetable and juice additives
to wheat flour tortillas is no more difficult to someone skilled in
the art than flavoring traditional loaf bread. In stark contrast,
corn masa dough does not readily accept any additives especially
ground garden vegetable and juice additives without severe
detrimental impact upon the performance of the dough.
[0008] There is a need in the art for flavored corn taco shells
that are not undesirably collapsed or closed and that are easy to
stack and package. Likewise, there is a need in the art for
flavored corn taco shells that have an opening of sufficient size
to fill such a taco shell with taco fillings in traditional and
self standing versions.
BRIEF SUMMARY OF THE INVENTION
[0009] In its product aspect one embodiment of the present
invention is flavored corn masa dough. The flavored masa dough
product comprises corn masa flour, water, seasoning blend, salt and
optionally added fat. The flavored masa dough product can also
optionally contain ground deep-fat fried flavored or unflavored
corn tortillas (regrinds). The flavored masa dough product can also
optionally contain minor portions of other cereal grain
ingredients. The flavored masa dough product can also optionally
contain minor amounts of natural or artificial color and
preservatives.
[0010] In another product aspect of the present invention is a
flavored corn tortilla fabricated from flavored corn masa dough.
The flavored corn tortilla comprises flavored corn masa dough
flattened into a round tortilla of desired diameter and thickness
cooked by applying heat to both sides until a desired moisture
content and doneness is achieved. Desired doneness can include
partially cooked to fully cooked flavored corn tortillas. Depending
on the final application, uncooked flavored tortillas are also
desirable.
[0011] In another product aspect the present invention is a
flavored corn masa taco intermediate fabricated from a flavored
corn masa tortilla shaped by a mold. The flavored taco shell
intermediate comprises a flavored corn masa dough tortilla of
desired diameter and thickness shaped by a mold. The flavored taco
intermediate is configured so the lip distance of the taco
intermediate is approximately 25% to 30% larger than the desired
lip distance of cooled deep-fat fried flavored taco shells.
Additionally, flavored taco shell intermediates of flavored
self-standing taco shells are configured with a lip distance 2.5 to
3 times the width of the base prior to deep-fat frying.
[0012] In still another product aspect the present invention is a
hot (about 150-180.degree. C.) deep-fat fried, flavored corn
tortilla taco shell fabricated from flavored corn masa taco
intermediates. The hot deep-fat fried, flavored corn tortilla taco
shells comprise flavored corn taco intermediates deep-fat fried in
hot cooking oil until a desired shape, moisture, residual oil
content and doneness are achieved. The hot deep-fat fried, flavored
corn tortilla taco shell is configured so the lip distance of the
hot flavored taco shell is approximately 25% to 30% larger than the
desired lip distance of cooled deep-fried flavored taco shells. Hot
deep-fat fried, flavored corn taco shells have a plastic pliable
texture. Additionally, hot deep-fat fried flavored self standing
corn taco shells are configured with a lip distance 2.5 to 3 times
the width of the base prior to cooling.
[0013] In still another product aspect the present invention is a
cooled or room temperature deep-fat fried flavored corn tortilla
taco shell obtained from hot deep-fat fried flavored corn tortilla
taco shells. The cooled deep-fat fried, flavored corn tortilla taco
shells comprise flavored corn masa taco intermediates deep-fat
fried in hot cooking oil until a desired shape, moisture, residual
oil content and doneness are achieved and subsequently cooled: The
cooled deep-fat fried flavored corn tortilla taco shell is
configured so that the lip distance of the cooled flavored taco
shell is approximately 25% to 30% smaller than the lip distance of
flavored taco shell intermediates and hot deep-fat fried flavored
corn taco shells. Cooled deep-fat fried flavored corn taco shells
have a solid crispy or frangible texture. Additionally, cooled
deep-fat fried flavored self standing corn taco shells are
configured with a lip distance 1.8 to 2.2 times the width of the
base.
[0014] In the preferred embodiment the cooled deep-fat fried,
flavored corn tortilla taco shells are stable, self-standing,
flavored taco shells with a first sidewall and a second sidewall
interconnected by a substantially flat base. The cooled deep-fat
fried, flavored self standing taco shell is configured so the
height of the taco shell is approximately 1.50 to 4.0 times the
width of the base.
[0015] In another embodiment, the cooled deep-fat fried flavored
self-standing, taco shell has a first sidewall and a second
sidewall interconnected by a substantially flat base. The cooled
deep-fat fried flavored taco shell is configured so that the height
of the cooled deep-fat fried flavored taco shell is approximately
about 50-110 millimeters and the width of the base is at least
10-15 millimeters. In another embodiment, the width of the base is
at least 19 millimeters. In yet another embodiment, the width of
the base is approximately 25 millimeters.
[0016] In another embodiment, the cooled deep-fat fried flavored
self-standing, taco shell has a first sidewall element, a second
sidewall element and a substantially flat base element. The flat
base element comprises a first curved segment interconnecting the
first sidewall element to a flat base segment, and a second curved
segment interconnecting the second sidewall element to the flat
base segment. In one embodiment of this flavored taco shell, at
least one of the elements will have a thickness of at least 1.5
millimeters. In one embodiment of this flavored taco shell, at
least one of the elements will have a thickness of less than 1.5
millimeters. In other embodiments of this flavored taco shell, the
curved segments may have large, medium or small radii.
[0017] In another embodiment, the cooled deep-fat fried flavored
self-standing, taco shell has a first sidewall element, a second
sidewall element and W-shaped base element. The W-shaped base
element comprises a first curvilinear segment interconnecting the
first sidewall element to an inversed curvilinear segment, and a
second curvilinear segment interconnecting the second sidewall
element to the inverse curvilinear segment. In one embodiment of
this flavored taco shell, at least one of the elements will have a
thickness of at least 1.5 millimeters. In one embodiment of this
flavored taco shell, at least one of the elements will have a
thickness of less than 1.5 millimeters. In other embodiments of
this flavored taco shell, the curvilinear segments proximate the
base can have large, medium or small radii.
[0018] In another embodiment, the cooled deep-fat fried flavored
taco shell has a first sidewall element, a second sidewall element
and a U-shaped base element. The U-shaped base element is
characteristic of traditional U-shaped tacos. The U-shaped base
element comprises a single curvilinear segment interconnecting the
first and second sidewall elements. The cooled deep-fat fried
U-shaped flavored taco shell has a minimum lip distance of 35 to 45
millimeters. In comparison, the lip distance of hot deep-fat fried
U-shaped flavored taco shells is 45 to 55 millimeters. The lip
distance of cooled deep-fat fried flavored "U" corn tortilla taco
shells is 20% to 40% smaller than the lip distance of hot deep-fat
fried flavored "U" corn tortilla taco shells.
[0019] The present invention, further resides in methods of making
flavored masa dough. In one embodiment, the method entails mixing
corn masa flour, water, seasoning blend, salt and optionally added
fat, color and preservatives. In another embodiment the method
entails grinding flavored or unflavored deep-fat fried corn
tortillas, commonly referred to as rework or regrinds, and admixing
to corn masa flour prior to blending with water, seasoning blend,
salt, and optional ingredients.
[0020] The present invention, in several embodiments further
resides in making flavored corn masa tortillas. In one embodiment,
the method entails portioning corn masa dough into small segments,
flattening small segments of flavored corn masa dough into round
tortillas of a desired diameter and thickness, and cooking by
applying heat to both sides until a desired moisture content and
doneness is achieved.
[0021] The present invention, in several embodiments, further
resides in methods of making a flavored corn masa taco shell
intermediate. In one embodiment, the method entails providing a
flavored soft flexible uncooked, partially cooked or fully cooked
corn masa tortilla and placing the tortilla in or on a mold. The
mold is configured so the resulting taco shell has a first sidewall
and a second sidewall interconnected by a substantially flat base,
a W-shaped base or a U-shaped base. The flavored taco intermediate
is configured so the lip distance of the taco intermediate is
approximately 25% to 30% larger than the desired lip distance of
cooled deep-fried flavored taco shells. Additionally, flavored taco
shell intermediates of flavored self-standing taco shells are
configured with a lip distance 2.5 to 3 times the width of the base
prior to deep-fat frying.
[0022] In one embodiment, the present methods of making a hot
deep-fat fried, flavored corn tortilla taco shell involves
providing a flavored corn masa taco shell intermediate. The
flavored corn masa taco shell intermediate is deep-fat-fried in hot
cooking oil until a desired temperature, shape, moisture, residual
oil content and doneness are achieved. The hot deep-fat fried,
flavored corn tortilla taco shell is prepared so the lip distance
of the hot flavored taco shell is approximately 25% to 30% larger
than the desired lip distance of cooled deep-fried flavored taco
shells. Additionally, hot deep-fat fried flavored self standing
corn taco shells are prepared with a lip distance 2.5 to 3 times
the width of the base prior to cooling.
[0023] In one embodiment, the present methods of making a cooled
deep-fat fried, flavored corn tortilla taco shell involves
providing a hot deep-fat fried flavored corn tortilla taco shell.
The hot deep-fat fried, flavored corn tortilla taco shell, hot from
deep-fat frying, is removed from the fryer and placed on its side
to cool until a desired temperature, shape, moisture and residual
oil content is achieved. The cooled deep-fat fried, flavored corn
tortilla taco shell is prepared so the lip distance of the cooled
flavored taco shell is approximately 25% to 30% smaller than the
lip distance of flavored taco shell intermediates and hot deep-fat
fried flavored corn tortilla taco shells. Additionally, cooled
deep-fat fried flavored self standing corn tortilla taco shells are
prepared with a lip distance 1.8 to 2.2 times the width of the
base.
[0024] In another embodiment, the present method of making a cooled
deep-fat fried self-standing, flavored taco shell includes
preparing a cooled deep-fat fried self-standing, flavored taco
shell where the height of the taco shell is approximately 1.50 to
4.0 times the width of the base.
[0025] In another embodiment, the present method of making a cooled
deep-fat fried flavored self-standing taco shell includes preparing
a cooled deep-fat fried flavored self-standing taco shell that has
a first sidewall and a second sidewall interconnected by a
substantially flat base. Further, the cooled deep-fat fried
flavored taco shell is prepared so that the height of the cooled
deep-fat fried flavored taco shell is approximately about 50-110
millimeters and the width of the base is at least 10-15
millimeters. In another embodiment, the method of making a cooled
deep-fat fried flavored self-standing taco shell includes preparing
a cooled deep-fat fried flavored self-standing taco shell so that
the width of the base is at least 19 millimeters. In yet another
method embodiment, the width of the base is approximately 25
millimeters.
[0026] In another embodiment, the present method of making a cooled
deep-fat fried flavored self-standing taco shell includes preparing
a cooled deep-fat fried flavored self-standing taco shell that has
a first sidewall element, a second sidewall element and a
substantially flat base element. Further, the cooled deep-fat fried
flavored taco shell is prepared so that the flat base element
comprises a first curved segment interconnecting the first sidewall
element to a flat base segment, and a second curved segment
interconnecting the second sidewall element to the flat base
segment. In one embodiment of the present method this flavored taco
shell is prepared so that at least one of the elements has a
thickness of at least 1.5 millimeters. In one embodiment of the
present method this flavored taco shell is prepared so that at
least one of the elements has a thickness of less than 1.5
millimeters. In other embodiments of the present method this
flavored taco shell is prepared so that the curved segments have a
large, medium or small radii.
[0027] In another embodiment, the present method of making a cooled
deep-fat fried flavored self-standing taco shell includes preparing
a cooled deep-fat fried flavored self-standing taco shell that has
a first sidewall element, a second sidewall element and W-shaped
base element. Further, the cooled deep-fat fried flavored taco
shell is prepared so that the W-shaped base element comprises a
first curvilinear segment interconnecting the first sidewall
element to an inversed curvilinear segment, and a second
curvilinear segment interconnecting the second sidewall element to
the inversed curvilinear segment. In one embodiment of the present
method this flavored taco shell is prepared so that at least one of
the elements will have a thickness of at least 1.5 millimeters. In
one embodiment of the present method this flavored taco shell is
prepared so that at least one of the elements will have a thickness
of less than 1.5 millimeters. In other embodiments of the present
method this flavored taco shell is prepared so that the curvilinear
segments have a large, medium or small radii.
[0028] In another embodiment, the present method of making a cooled
deep-fat fried flavored taco shell includes preparing a cooled
deep-fat fried flavored taco shell that has a first sidewall
element, a second sidewall element and a U-shaped base element.
Further, the cooled deep-fat fried flavored taco shell is prepared
so that the U-shaped base element comprises a single curvilinear
segment interconnecting the first and second sidewall elements. In
one embodiment of the present method this cooled deep-fat fried
U-shaped flavored taco shell has a minimum lip distance of 35 to 45
millimeters. In comparison, the lip distance of hot deep-fat fried
U-shaped flavored taco shells is 45 to 55 millimeters.
[0029] While multiple embodiments are disclosed, still other
embodiments of the present invention will become apparent to those
skilled in the art from the following detailed description, which
shows and describes illustrative embodiments of the invention. As
will be realized, the invention is capable of modifications in
various obvious aspects, all without departing from the spirit and
scope of the present invention. Accordingly, the drawings and
detailed description are to be regarded as illustrative in nature
and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is an end elevation view of a flavored corn masa taco
intermediate in a wide taco mold.
[0031] FIG. 2 is an end elevation view of a deep-fat fried flavored
"flat" self standing corn masa tortilla taco shell resting on its
side on a planar surface.
[0032] FIG. 3 is an end elevation view of a deep-fat fried flavored
self standing corn masa tortilla taco shell having a "W" shaped
base resting on its side on a planar surface.
[0033] FIG. 4 is an end elevation view of a deep-fat flavored "U"
corn masa tortilla taco shell resting on its side on a planar
surface.
[0034] FIG. 5 is a flow chart illustrating a method of
manufacturing a flavored taco shell.
DETAILED DESCRIPTION
[0035] In its product aspect one embodiment of the present
invention is flavored corn masa dough. The flavored masa dough
product comprises preferably about 47-57% corn masa flour by weight
(dry basis), 39-49% moisture by weight, 1-5% seasoning blend by
weight (dry basis), 1-5% salt by weight (dry basis) and less than
0.5% added fat by weight (dry basis). The masa dough product can
also optionally contain 3-6% ground deep-fat fried flavored corn
taco shells by weight (dry basis), commonly referred to as regrinds
or rework. The masa dough product can also optionally contain 1-3%
other grain ingredients by weight (dry basis) for example ground
oat, wheat or barley. The masa dough product can also optionally
contain minor amounts less than 0.5% preservatives by weight (dry
basis) and 0.5% natural or artificial color by weight (dry
basis).
[0036] Throughout the specification and claims, percentages are by
weight and temperatures in degrees Celsius unless otherwise
indicate. Each referenced patent or patent application is hereby
incorporated by reference.
[0037] Masa means "dough" in Spanish, but in Mexico it is generally
understood as corn dough. Masa is made by boiling corn kernels in
powdered unslaked lime (calcium oxide), washing them and then
grinding. Enough water is then mixed into the meal to make a thick
paste or dough. Smoother, soft masa is required for tortillas, and
coarser, stiff masa is used for tamales. "Masa harina" is
factory-made, powdered masa, i.e., flour ground from corn kernels
that have been soaked in slaked lime that is often sold in bulk.
Masa harina can be used to make anything that calls for masa. Masa
harina is thus to be distinguished from mere corn flour that has
not been lime slaked and heated.
[0038] Any commercially available corn masa flour can be selected
for use in flavored masa dough. For example, commercially available
corn masa flour can be obtained from Cargill, Inc. located in
Minnesota USA. Corn masa flour is commonly available in white and
yellow varieties and is sold ground to fine, medium and course
particulate sizes. Corn masa flour is also available in less common
color varieties such as blue, black and red, one skilled in the art
of product formulation would have little difficulty substituting a
color variety to suit the end application. Yellow coarse masa flour
is preferred for flavored taco shell applications. Otherwise, color
and particulate size of corn masa flour can be subjectively
selected by the product developer to match the desired application
of the finished flavored corn masa product. Any product developer
skilled in the art will have little difficulty selecting corn masa
flour suitable to make flavored corn masa dough of the desired
color and texture preferred.
[0039] While preferred for use herein are masa doughs comprising
one or more corn (maize) flour ingredients (e.g., a mixture of
white and yellow corn flours), the skilled artisan will appreciate
that in less preferred embodiments, the masa dough can include
minor amounts of one or more farinaceous ingredients such as flours
from other non-maize cereal grains (major cereal grains such as
barley, wheat, rice or oats), or their starch fractions.
[0040] Any potable water can be selected for use in flavored masa
dough. Municipal drinking water of relatively neutral pH 6-8 is
preferred because of cost and availability. Good results are
obtained when the masa dough has a moisture content ranging from
about 39-49%.
[0041] Seasoning blends suitable for flavoring corn masa dough are
preferably dried and may or may not contain dairy ingredients.
Dried ground garden vegetables herbs and spices and mixtures
thereof are all suitable for creating a seasoning blend. Dried
ground garden vegetables can include but is not limited to celery,
carrot, tomato, onion, peppers (all varieties), beets, broccoli,
spinach, and kale. Dried ground herbs and spices can include but is
not limited to basil, rosemary, thyme, oregano, chives, garlic,
peppercorns, cloves, cinnamon, paprika, cumin, anise, mustard and
ginger. Dried seasonings may additionally contain minor amounts of
preservatives, fillers and anti-caking or flowing agents to extend
the shelf-life and ease of use of these ingredients. Seasoning
blends may contain dairy ingredients and flavorings to impart dairy
flavors in flavored masa dough such as nacho cheese. Dairy
ingredients may include but are not limited to dried ground cheese,
cheese powder, whey powder, dried milk powder and combinations
thereof. Highly concentrated liquid seasoning or extracts may also
be used, but are less preferred because of their cost and the
adjustments required to the formula to account for the added
moisture these ingredients provide.
[0042] Any commercially available food grade salt (sodium chloride)
is suitable for use in flavored corn masa dough. Medium ground salt
or finer is preferred to facilitate mixing and blending into
flavored corn masa dough. Mixtures of sodium chloride and potassium
chloride can also be used to provide reduced sodium content food
products. It is important to have the salt incorporated into the
corn masa dough in order to enhance the seasoning blend. While
increased amounts of salt are desirable to boost the impact of the
seasoning blend, increased amounts of salt exaggerate problems of
increased plasticity of the dough. While flavored masa dough can be
prepared with less salt that exhibit reduced plasticity and
therefore less lip distance reduction, such products can be
perceived by consumers as bland or deficient in flavor. Of course
the flavor impact of flavored corn tortilla taco shells can be
increased by increasing seasoning blend content level, however
since such seasoning ingredients are ten times more expensive than
corn masa flour such high levels greatly increase the total cost of
finished products. For this reason it is important that salt is
incorporated vs. topically applied.
[0043] Minor amounts of commercially available edible animal or
vegetable fat may optionally be added to flavored corn masa dough.
Added fat is to be distinguished from fat contributed by corn masa
flour or cheese ingredients. A product developer skilled in the art
may selectively add fat as a processing aid, component of a
seasoning ingredient or component of a ground fried flavored taco
shell rework or regrind ingredient. Good results can be obtained
when the formulation fat ingredient is less than 0.5% of an edible
fat or shortening ingredient. Also, while hydrogenated fats,
especially derived from vegetable oils can be used, current
consumer heath interest favor use of non-hydrogenated liquid oils
especially vegetable oils rather than solid or semi-solid fats such
as from hydrogenated fats to reduce the levels of undesirable trans
fatty acids.
[0044] Flavored masa dough can optionally contain ground deep-fat
fried flavored taco shells (e.g., rework or regrinds). Ground
deep-fat fried flavored taco shells are made by grinding fried
flavored taco shells into pieces 1-10 millimeters in diameter. Any
product developer skilled in the art would have little difficulty
selecting a food mill or blender capable of grinding deep-fat fried
flavored taco shells to a reasonably uniform size to create this
optional rework ingredient.
[0045] Flavored masa dough can also optionally contain other grain
ingredients for example ground oat, wheat or barley. Such grain
based flour materials are commonly available. A product developer
skilled in the art may selectively add other ground grains to
enhance the color, flavor or handling properties of flavored corn
masa dough or one of its many end products depending on the
application.
[0046] Flavored masa dough can also optionally contain minor
amounts of preservatives. A product developer skilled in the art of
food formulation will have little difficulty obtaining commercially
available food grade preservatives. Any of the know antimicrobial
or antioxidant food preservatives can be selectively used in
flavored corn masa dough to extend product shelf-life. The products
herein can additionally include common levels and types of
anti-oxidants and preservatives such as vitamin E, BHA (Butylated
hydroxyanisole), BHT (butylated hydroxytoluene), TBHQ (Tert-Butyl
Hydroquinone), and mixtures thereof, up to levels permitted by
current food laws.
[0047] Flavored masa dough can also optionally contain minor
amounts of natural or artificial color. To enhance the color of
flavored corn masa dough natural or artificial color can be
selectively used. One such food color ingredient is annatto which
can enhance the yellow color of the finished shells preferred for
use herein are flavor and color additives intended to mimic the
yellow color of traditional yellow corn. While in certain
jurisdictions, certain synthetic yellow colorants are permitted,
especially useful herein for such color additives are those natural
yellow colorants such as turmeric, beta carotene, and/or annatto.
Other color ingredients may be selected purely to enhance the
flavor perception of flavored corn masa dough. For example, red
color may be used to enhance the perception of tomato flavor. Some
manufacturers may elect to rely solely on color to convey a
perceived flavor.
[0048] Another product aspect of the present invention are flavored
corn masa tortillas. Generally round in shape, flavored corn
tortillas comprise flavored corn masa dough flattened to a
thickness of at least 1.5 millimeters. Depending on the application
for the finished flavored tortillas, flavored corn masa dough is
flattened or cut to a diameter of 40-60 millimeters for tortilla
chips, 60-80 millimeters for mini tacos, 120-180 millimeters for
traditional tacos and 250-350 millimeters for burritos and
wrap-style sandwiches. Preferred for use herein are tortillas
ranging from about 120-180 millimeters in diameter and weighing
about 10 to 30 grams each. In preferred variations, the tortillas
each range from about 10-20 grams and for best results between
10-15 grams. Tortillas are cooked by applying heat to both sides or
flash baking until a desired moisture content and doneness is
achieved. Desired doneness can include partially to fully cooked
tortillas. Selected applications may use uncooked tortillas. One
skilled in the art of food processing will have little difficulty
selecting a device for cooking tortilla shells. Commercial
production of tortillas has made industrial sized tortilla formers
and cookers widely available.
[0049] Another embodiment of flavored corn masa tortillas are
partially cooked flavored corn masa tortillas. The partially cooked
flavored corn masa tortilla article comprises on a dry basis
preferably about 47-57% corn masa flour by weight (dry basis),
15-30% moisture by weight, 1-5% seasoning blend by weight (dry
basis), 1-5% salt by weight (dry basis) and 0.1-1% added fat by
weight (dry basis). Flavored corn masa tortillas can also
optionally contain minor amounts of rework or regrinds 3-6% by
weight (dry basis), other grain ingredients 1-3% by weight (dry
basis), preservatives less than 0.5% by weight (dry basis) and
natural or artificial color 0.5% by weight (dry basis). While
describing the composition of the partially cooked flavored corn
masa tortilla article on a dry basis demonstrates the consistent,
range of ingredients from flavored corn masa dough to flavored corn
masa tortilla to flavored corn masa taco intermediate to flavored
corn tortilla taco, it is common to also describe similar
compositions on a wet basis. The partially cooked flavored corn
masa tortilla article comprises on a wet basis preferably 65-72%
corn masa flour by weight, 15 to 30% water by weight, 2-6%
seasoning blend by weight, 2-5% salt by weight and 0.1 to 1% added
fat by weight. Flavored corn masa tortillas can also optionally
contain on a wet basis minor amounts of rework or regrinds 4-7% by
weight, other grain ingredients 2-4% by weight, preservatives less
than 1% by weight and natural or artificial color 1% by weight.
[0050] Another product aspect of the present invention is a
flavored corn masa taco shell intermediate. Referring now to FIG.
1, there is seen an end elevation view of a flavored taco shell
intermediate 10 on a wide taco mold 2. The flavored corn masa taco
shell intermediate 10 starts as a circular flavored corn masa
tortilla 3 shaped by the wide taco mold 2. A chain mesh cover 4
holds the corn masa tortilla 3 on the wide taco mold 2. The wide
taco mold 2 imparts a desired "flat" self standing taco shape to
the flavored corn masa tortilla 3 forming the flavored taco shell
intermediate 10. The flavored corn masa taco shell intermediate 10
has a pair of opposed sidewalls 5 that are interconnected by a flat
base 6. Flavored corn masa taco shell intermediates 10 have a base
width (represented by the letters "Db") of about 25.+-.10
millimeters (15-35 millimeters). The pair of opposed sidewalls 5
have a top edge 7. The top edge 7 of each sidewall 5 is free of
connection to the opposed sidewall 5. Flavored taco shell
intermediates 10 have a lip distance 8 defined as the total
distance between the top edge 7 of the opposed sidewalls 5 of about
65 to 75 millimeters that is 2.5 to 3 times the base width Db of
about 25 millimeters. In comparison, the lip distance 8 of flavored
taco shell intermediates 10 is 25% to 30% larger than the lip
distance of cooled deep-fat fried flavored taco shells.
[0051] In still another product aspect the present invention is a
deep-fat fried flavored corn tortilla taco shell fabricated from a
deep-fat fried flavored corn masa taco intermediate. Deep-fat fried
flavored corn tortilla taco shells in addition to the deep-fat
fried flavored corn masa taco intermediate contain 5-35%,
preferably 25% or less absorbed cooking or frying oil and 8% or
less residual moisture. Cooking oil or frying oil may include any
commercially available animal or vegetable oils. Animal and
vegetable cooking oils or frying oils can be used interchangeable
and include but are not limited to beef tallow or pork lard, corn
oil, soybean oil, canola oil, peanut oil or combinations thereof.
Cooking or frying oils may be partially or fully hydrogenated and
contain preservatives to extend shelf-life. Soybean oil is
preferred because of its neutral flavor, cost and availability.
[0052] In a preferred embodiment, deep-fat fried flavored taco
shells are stable and self standing. FIG. 2 is an end elevation
view of a flavored "flat" self-standing taco shell 100 formed from
a circular tortilla. The flavored finished self-standing taco shell
100 is depicted on its side resting on a flat surface 105. The
flavored self-standing taco shell 100 has a pair of opposed
sidewalls 110 that are interconnected by a flat base 120. The pair
of opposed sidewalls 110 have a top edge 130. The top edge 130 of
each sidewall 110 is free of connection to the opposing sidewall
110, creating the open end 140 of the shell 100.
[0053] The flavored self-standing taco shell 100 is hot (about 150
to 1800.degree. C.) immediately after deep-fat frying. When the
flavored free standing taco shell 100 is hot it is in a soft
plastic state. Still referring to FIG. 2, when the flavored free
standing taco shells 100 are hot they have an initial lip distance
150 defined as the total distance between the top edge 130 in an
initial position 130a of the opposed sidewalls 110 in a initial
position 110a. The initial lip distance 150 of hot flavored
self-standing taco shells 100 is relatively large approximately 60
millimeters, however gravity immediately causes the opposed
sidewalls 110 in their initial position 110a to converge
compressing or reducing the initial lip distance 150 to a final lip
distance 160 as the hot flavored self-standing taco shell 100
cools. As flavored self-standing taco shells 100 cool from a hot
temperature range of about 150 to 180.degree. C. to temperatures
below about 140.degree. C. their soft plastic state transforms to a
solid crispy more frangible state. In this solid more frangible
state the final lip distance 160 is set. Flavored flat bottom taco
shells also have a cooled lip distance 160 defined as the total
distance between the top edge 130 of the opposed sidewalls 110
after cooling. The preferred minimal lip distance 160 for flavored
self-standing taco shells 100 is about 55 millimeters.
[0054] Still referring to FIG. 2, in another embodiment deep-fat
fried self-standing flavored taco shells 100 upon removal from the
deep fat fryer are hot about 150 to 180.degree. C. The initial lip
distance 150 of hot deep-fat fried flavored taco shells 100 is
larger than the final lip distance 160 of cool deep-fat fried
flavored taco shells 100 for example, about 25% to 35% larger.
[0055] Still referring to FIG. 2, deep-fat fried self-standing
flavored taco shells 100 have a base width (represented by the
letters "Db") of about 25 millimeters. In another embodiment
deep-fat fried flavored taco shells 100 upon removal from the deep
fat fryer are hot about 150 to 180.degree. C. The initial lip
distance 150 of hot deep-fat fried flavored taco shells 100 can be
2.5 to 3 times the base width Db. The final lip distance 160 of
cool deep-fat fried flavored taco shells 100 is 1.8 to 2.2 times
the base width Db.
[0056] Still referring to FIG. 2, deep-fat fried self-standing
flavored taco shells 100 have a shell height (represented by the
letters "Dh") preferably of about 50 to 110 millimeters. In another
embodiment deep-fat fried flavored taco shells 100 have a shell
height Dh 1.50 to 4.0 times the base width Db. One skilled in the
art can appreciate that a food trough can be created with a Dh of
about 12 to 50 millimeters as described in patent application
PCT/US02/36474 Square Bottom Taco Shell, Kovich et al.
[0057] Still referring to FIG. 2, the flat base 120, of the self
standing flavored taco shell 100, comprises a flat segment 170,
that is bordered by two curved segments 180. Each curved segment
180 serves as a transition from the flat base 120 to the sidewalls
110. In one embodiment of the invention, as described in patent
application PCT/US02/36474 Square Bottom Taco Shell, (equivalently,
US 2006/0147587 published Jul. 6, 2006) by Kovich et al., the radii
of the curved segments 180 are large (approximately 6 millimeters
or greater), forming rounded transitions from the flat base 120 to
the sidewalls 110. In another embodiment of the invention, the
radii of the curved segments 180 are medium (approximately 6
millimeters to 3 millimeters). In still another, embodiment of the
invention, the radii of the curved segments are small
(approximately 3 millimeters or less), forming transitions from the
flat base 120 to the sidewalls 110 that have a profile with a very
pronounced edge.
[0058] FIG. 3 is an end elevation view of a deep-fat fried flavored
"W" self standing taco shell 200 formed from a circular flavored
tortilla (reminiscent of those shells as described in greater
detail in U.S. Pat. No. 5,993,871 "Stable, Self-Supported Taco
Shell"). The deep-fat fried flavored "W" self standing taco shell
200 is depicted on resting on its side on a planar surface 205. The
deep-fat fried flavored "W" self standing taco shell 200 has a pair
of opposed sidewalls 210 that are interconnected by a W-shaped base
220. The W-shaped base 220 has a pair of opposed curvilinear
segments 280. The opposed curvilinear segments 280 interconnect the
sidewall 210 to an inversed curvilinear segment 270. The
convergence of the opposed side walls of hot deep-fat fried
flavored "W" self standing corn tortilla taco shells mirrors that
of deep-fat fried flavored "flat" self standing corn tortilla taco
shells.
[0059] FIG. 4 is an end elevation view of a deep-fat fried flavored
"U" corn tortilla taco shell 300 formed from a circular flavored
tortilla. The deep-fat fried flavored "U" corn tortilla taco shell
300 is depicted resting on its side on a planar surface 305. The
deep-fat fried flavored "U" corn tortilla taco shell has a pair of
opposed walls 310 that are interconnected by a U-shaped base 320.
The pair of opposed walls 310 have a top edge 330. The top edge 330
of each sidewall 310 is free of connection to the opposing sidewall
310, creating an open end 340 of the deep-fat fried flavored "U"
corn tortilla taco shell 300. The deep-fat fried flavored "U" corn
tortilla taco shell 300 is hot (about 150 to 180.degree. C.)
immediately after deep-fat trying. When the deep-fat fried flavored
"U" shaped corn tortilla taco shell 300 is hot it is in a soft
plastic state. When the deep-fat fried flavored "U" shaped corn
tortilla taco shells 300 are hot they have an initial lip distance
350 defined as the total distance between the top edge 330 in an
initial position 330a of the opposed sidewalls 310 in an initial
position 310a. The initial lip distance 350 of hot deep-fat fried
flavored "U" corn tortilla taco shells 300 is relatively large
approximately 45 to 55 millimeters, however gravity immediately
causes the opposed sidewalls 310 in their initial position 310a to
converge compressing the initial lip distance 350 to a final lip
distance 360 as the hot deep-fat fried flavored "U" corn tortilla
taco shell 300 cools. The final lip distance 360 of cooled deep-fat
fried flavored "U" corn tortilla taco shells 300 is approximately
about 35 to 45 millimeters. As deep-fat fried flavored "U" corn
tortilla taco shells 300 cool from a hot temperature range of about
150 to 180.degree. C. to temperatures below about 140.degree. C.
their soft plastic state transforms to a solid more frangible
state.
[0060] Still referring to FIG. 4, in another embodiment deep-fat
fried flavored "U" corn tortilla taco shells 300 upon removal from
the deep fat fryer are hot about 150 to 180.degree. C. The initial
lip distance 350 of hot deep-fat fried flavored "U" corn tortilla
taco shells 300 is 20% to 40% larger than the final lip distance
360 of cool deep-fat fried flavored "U" corn tortilla taco shells
300.
[0061] Another embodiment of the present invention is deep-fat
fried flavored corn tortilla taco shells. The deep-fat fried
flavored corn tortilla taco shell article comprises on a dry basis
preferably about 47-57% corn masa flour by weight (dry basis),
15-30% absorbed cooking or frying oil by weight (dry basis), 2-8%
moisture by weight, 1-5% seasoning blend by weight (dry basis),
1-5% salt by weight (dry basis) and 0.1-1% added fat by weight (dry
basis). The deep-fat fried flavored corn tortilla taco shell
article can also optionally contain minor amounts of rework or
regrinds 3-6% by weight (dry basis), other grain ingredients 1-3%
by weight (dry basis), preservatives less than 0.5% by weight (dry
basis) and natural or artificial color 0.5% by weight (dry basis).
While describing the composition of the deep-fat fried corn
tortilla taco shell article on a dry basis also demonstrates the
consistent, range of ingredients from flavored corn masa dough to
flavored corn masa tortilla to flavored corn masa taco intermediate
to flavored corn tortilla taco, it is common to also describe
similar compositions on a wet basis. The deep-fat fried corn
tortilla taco shell article comprises on a wet basis preferably
70-78% corn masa flour by weight, 15-30% absorbed cooking or frying
oil by weight, 2 to 8% water by weight, 2-6% seasoning blend by
weight, 2-5% salt by weight and 0.1 to 1% added fat by weight. The
deep-fat fried flavored corn tortilla taco shell article can also
optionally contain on a wet basis minor amounts of rework or
regrinds 4-7% by weight, other grain ingredients 2-4% by weight,
preservatives less than 1% by weight and natural or artificial
color 1% by weight.
[0062] A process of making the self-standing taco shell 100 will
now be described by referring to the process flow chart illustrated
in FIG. 5. Initially, a flavored masa dough is formed. As one of
ordinary skill in the art would recognize, this can be done by
purchasing masa dough from a vendor and subsequently flavoring it,
purchasing masa flour and mixing it with water, seasoning blend,
salt, annatto (an optional yellow coloring) and optionally rework
to form flavored masa dough (block 400), or by purchasing raw corn
and processing it to make flavored masa dough. If raw corn is
purchased, the raw corn is cooked with lime and then steeped. The
corn is then washed and ground into masa paste, which is then mixed
with other ingredients to form the flavored dough.
[0063] The present methods of preparation can additionally include
a dough sheeting step to form the masa dough into suitably shaped
and sized individual pieces such as tortillas. The dough sheeting
steps can be practiced by dough entering the sheeting machine,
which forms raw flavored masa tortillas (block 410). In one
embodiment of the invention, the flavored tortillas will have a
thickness of less than 1.5 millimeters. In another embodiment of
the invention, the flavored tortillas will have a thickness of
approximately 1.5 to 3.0 millimeters or greater. Also, while the
present invention finds particular suitability for use in
connection with the provision of corn or maize based masa flour,
the skilled artisan will appreciate that the present invention
finds usefulness in provision of other grains such as wheat for
wheat/corn blends based formed flavored taco shells.
[0064] The present methods can additionally comprise a step of
flash baking. The raw flavored masa tortillas can optionally then
be flash baked, resulting in raw flavored masa tortillas with toast
marks (block 420) as well as a reduced moisture content so as to
thereby minimize fat take-up during the subsequent frying step. The
toasted still soft and flexible flavored tortillas are then formed
into self-standing flavored taco shell intermediated having
substantially flat bases (block 430).
[0065] During the forming process, the tortillas are placed on
molds and the tortillas conform to the molds (block 430). The molds
can be a wire mesh mold, a wire cage mold, a combination wire
mesh/cage mold, or a conventional mold having upper and lower
plates. In either case, the molds are flat-bottomed and have
cross-sectional elevations like the self-standing taco shells 100
shown in FIG. 2, or are "W" bottomed and have cross-sectional
elevations like the "W" taco shells 200 shown in FIG. 3, or are "U"
bottomed and have cross-sectional elevations like the "U" taco
shells 300 shown in FIG. 4 and as discussed above. Like the self
standing taco shells 100 illustrated in FIG. 2, the curved segments
of the mold may have large, medium or small radii as discussed
above.
[0066] Still referring to block 430, in the production of self
standing flavored "flat" taco shells 100 shown in FIG. 2, the molds
are designed to create the flavored taco intermediate 10 shown in
FIG. 1, with a lip distance 8 that is 25% to 30% larger than the
cooled deep-fried flavored "flat" corn tortilla taco shell 100.
Likewise, in the production of self standing flavored "W" taco
shells 200 shown in FIG. 3, the molds have a lip distance that is
25% to 30% larger than the cooled deep-fried flavored shell.
Similarly, in the production of "U" taco shells 300 shown in FIG.
4, the molds have a lip distance that is 20% to 40% larger than the
cooled deep-fried flavored shell.
[0067] The conformed flavored taco shell intermediates are then
fried and adopt the form of the molds (block 440). The flavored
taco intermediates exit the fryer on their sides as fried flavored
self-standing "flat" taco shells, fried flavored self-standing "W"
taco shells or traditional "U" taco shells at a temperature of 150
to 180.degree. C. and a moisture content of less than about 8%.
Since the formed flavored tacos are still plastic or pliable while
still hot immediately after frying, placing the shells on their
sides allows gravity to act upon the shells causing a convergence
of the opposed sidewalls. The taco intermediates and hot taco
shells are purposely designed to be 25% larger than the cooled
deep-fat fried shells to take advantage of this convergence.
[0068] Oil drains from the flavored taco shells as the opposed
sidewalls converge until cooled sufficiently (block 450) to harden.
In another embodiment, the flavored tortillas are baked to a final
moisture content of less than 8% to form low fat shaped rigid
flavored tacos. A number (e.g., 3-6) of the cooled hardened rigid
flavored taco shells are then nested (block 460) together into
nested quantities and these nested quantities preferably provided
with an intermediate spacer (not shown) and packaged (block 470)
such as by providing one or more of the nested quantities onto a
support board and then a film over wrap.
[0069] Minimizing the formation of discontinuities (e.g., bubbles
and voids) in a flavored taco shell can be a challenge when
commercially producing flavored taco shells. Discontinuities in
flavored taco shells can be minimized by providing masa flour of
the proper granulation, properly blending the dry ingredients,
using the proper ratios of ingredients, maintaining the proper
moisture level in the flavored dough, baking and frying properly,
and avoiding the use of taco shell molds having complex geometries.
Because the flat-bottomed molds have simple geometric
characteristics, the tortillas readily conform to the molds,
minimizing the potential for the formation of destabilizing
discontinuities, especially those at the base 120 of the shell 100
shown in FIG. 2.
[0070] It will be appreciated that by maintaining the lip distance
sufficiently to provide an open finished taco shell, a number of
individual taco shells can be nested together (e.g., 3-6) to
provide a nested array of square bottomed taco shells. Such an open
configuration allows for minimizing breakage of the fragile
finished shells during packaging including forming a nested array
of such shells. Importantly, by providing such an open
configuration, mechanical nesting apparatus can be employed to
provide such a nested shell array (See, for example, US
2005/0050858 "Taco Shell Nesting Apparatus and methods" published
Mar. 3, 2005 by Cremers et al.) instead of time consuming and
costly hand assembly.
[0071] A quantity (e.g., 3-6) of such flavored square bottomed taco
shells of the present invention can be provided in the form of a
nested array (not shown) and provided in a suitable consumer food
packaging such as being mounted upon a paperboard support such as
U-board and over wrapped with a flexible packaging film (e.g. A
clear shrink-wrap packaging film). If desired, a spacer insert can
be provided between the sides of the top nested shell to provide
additional protection against breakage such as by unintended
compression of the packaged food article. In preferred articles,
the wrapped nested array of taco shells is disposed within an outer
protective carton.
[0072] While the present flavored taco shells can be provided with
an additional or supplemental topical flavoring feature, in the
preferred embodiment the flavored taco shells are free of any such
additional or supplemental seasoning or flavoring. Such shells free
of any surface or topical supplemental seasoning provide additional
consumer consumption convenience by reducing the tendency of any
such topical seasoning to undesirably transfer to the consumer's
finger during handling whether during preparation or
consumption.
[0073] Although the present invention has been described with
reference to preferred embodiments, persons skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention.
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